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Kansai Nerolac Paints
3 Wet Technology - An Innovative Application System for Painting
4-Wheeler Sector in Automobiles |
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| ORGANIZATION PROFILE |
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Kansai Nerolac Paints Limited (KNPL) is a subsidiary of Kansai Paints Japan, having turnover more than 1600 Cr. INR. The business line of KNPL are (a) Industrial Paints(b) Decorative paints (c) Powder Coating (d) High Performance coating (e) Pretreatment coating. The second largest paint company of India ,KNPL is the market leader of industrial & Automotive paints and have 20% of total market. Market is serviced by 4 own plants and few outsourced units. The key industrial customers includes Maruti Udyog, Toyota, Tata Motors, Godrej. For decorative coating KNPL is using a 11000 strong dealer network serviced through 65 depots. |
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| BEST PRACTICE CATEGORY |
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10.0 Improvement and Innovation |
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| MANAGERIAL PRACTICE WITHIN BUSINESS PRACTICE |
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10.13 Innovation |
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| APPROACH USED TO ACCOMPLISH PRACTICE |
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Customer's expectations are saving on energy, increased throughput, space saving, reduction in Manpower and reduced material cost. |
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Joint laboratory work was done along with Principals to identify the possible solutions |
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Process finalization done along with customer |
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| MACRO FLOW CHART OF PRACTICE |
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| DEPLOYMENT OF PRACTICE |
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This was a joint exercise with the customer before they constructed the new painting facility |
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Painting system was discussed and agreed upon with the customer |
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Finalization of type of equipment to be deployed |
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Installation of robotics based painting application facility at our plant which is identical with the facility available at customer |
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Reproduced the appearance by Simulating customer's process parameters |
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Customer constructs the painting facility |
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Trials taken at Customers' end which turned out to be successful. |
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| IMPROVEMENT ACCOMPLISHED IN PRACTICE |
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| 1. |
Reduction in baking Energy consumption |
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Productivity increase ( Increase in Throughput) |
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| INNOVATIONS ACCOMPLISHED IN PRACTICE |
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| 4 Wheel Automobile industries has been traditionally practicing 4 coat system in the following sequence. |
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| In this system 2 times baking is involved which is eliminated in the 3 wet system. The process followed for 3 wet system comprises of: |
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| ALIGNMENT OF PRACTICE WITH ORGANIZATIONAL NEEDS |
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To lay emphasis upon our leadership in Automobile paints |
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| BENEFITS |
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Benefit for customer: |
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Increase in throughput |
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Saving in power & fuel (baking energy) |
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Reduction in Material cost |
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Benefit for KNPL |
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Being Sole supplier to Maruti Suzuki India Limited, Manesar. Organisational growth is directly proportional to the growth of customer |
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This is a industry benchmark by itself (done first time in India) |
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| AUTHOR |
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Shashank D Puro
Chief Manager - Technical |
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| Back to winners |
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| Back to winners |
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